Process for the manufacture of insulation units



106. comPo nw 3 Cfbs Refernbd xaminr comma 0R Pustm Jan. 26, 1943. N. E. NEWMAN 5 PROCESS ron THE mumm 0F msumuou uurrs Y 4 Filed Jam-27,1942 {Sheets-Shoal f fw nae-saves /cmman $UCTION FAN B STEAM EXHAUST 4 BATTIEY or ogswrzeaenroes.

INVENTOR lVfiTl-lA/V NEWMAN ATTORQIEYS oMPosmouQ I v gonme 0R PLASTIC bl'OSS Reference gxammer Jan. 26,1943. u.':. NEWMAN 2,309,205 rnocsss FOB m: muum c'runsi OF msumnou UNITS I Filed an. 27, 1942 ZSheets-Slieqt 2 TEMPERATURE F TI-TE. MEAN TEMPERATURE .F

v "warn-01 a Warm/v E. flaw/1n ATTORNEYS excess moisture is evaporatedn It i'sfthen re 1 {m the field or structural agents 85% mag i;-

V v ritocnss FORTHEMANUFACTURE F jv INSULATION UNITS Nathan 1 Newman, Bronxyille, N; Y1; assigno as j I Asbestos Limited Incorporated,'NewYork a corporation'of New York Application was z7;'1942,seria,i No

se i-" 42.; conductivity of fa 5: 75- magnesia and the inven vnesia" plays an important role. It istho'weve'rf v t deficient in many respects. Athigh temperature, fang-6 1s a similar graph illustratingthe relaits thermal conductivity is excessive; its breaking load is low; its shrinkage 1s unduly severe; and its J -I have perfected a process for producing ihsula 7' tion ot this general type which eliminates the foregoing disadvantages inherent in'conventional in g n v I- :11 carrying out theinvention, asbestos, c'on stituting onetype' o'f fiber 'which' may be eniployed, is defiberizedinto its approximate ulti mate filaments and then mixed with a preponder fibers held together by a binder, initially semso .and strengthgllr a: I loss inweight notable. Then, too, it calcines at l tion hereini nd tive effect for temperatureon weight, shrinkage integrators 'A. Through impact, and extreme pressure created. by suction Ian B, the fibers are broken down into innumerable very short, slendercomponents, which are carriedofi to the collector C, from whence they areldeposited in the mixer to speak, and with countless interstices or voids 1' 2'? between the set fibers. Then the unit is cured c; any suitable manner.. By way of lexamplef and' assuming that an'acceleration oi thesetting' of the spaced relationship of the fibers is desired, it may be introduced into a chamber under steam product is the countless voids or'air pockets pres D.-.- Some idea may be gained with respect to the transition of the asbestos from its original state I to its ultimate form when itis said that 80 pounds ance-of water and a binder; subsequentlyQtlie l f' slurry is placed in a mould where it is lightly com-f pressed, and then permitted to settle and the} surplus water to drain; 'There remains a mass of.

01 raw fiber will develop'40 to 50 times in bulk. 'As stated; the fibers are short-in contradistinction ningor' weavingoperations-q -v a 1 .fAlso-inmixer D are added an excess quantity ofwatenior example, approximately '75 gallons or, '625- pounds,-42-po'un"ds of cement-and 12 pounds 3 of silica sand, preferably pulverized, or other suit-- pressure for several hours. .In any event, after -I' able silicious material, as high temperature clay 12%"..x 3 /47") until it is completely filled. Here ent in a given area of the block or bar---ur'1do1 ibt edly due, primarily, to thefmaximum degree to which the asbestos fibers are disintegrated at the outset, taken in: conjunction with. themeans,

the mass Kremlightly combressed, say, about other and then permanently held in such relationship. A- superior insulation is thus obtained; Other objects and advantages will appeariroin i theifollowing explication taken in conjunction- .---sz-m;'4 is a-fra'gmentary section of the unit} greatly magnified;

Fig. 5 is a graph indi ating the lease thesis meansofanydevice suited for-the purpose, as a reticulated frame I l, to free it'oi' any unduly large whereby they are intimately associated with each entrapments of water'or air and thereby insure an initial 'nnitorm density. fTo regulate the amount of compression 'to' anicety, the insidewalls of the mould are provided with stops l 2 a short distance below the top edgesoi the mould which are engaged bythe lower portion of the frame I I f as the latter is constrained downwardly within said mould. within an hourbr so the water drains through the 'foraminousbottom of the, v

mould and the mass settles rapidly therein; In

f this manner,-owing to the over-abundant supply A-quantity of asbestos fiber raw statefsay; lbs is fed into hopper ll] of a battery of dis:

or water, the-individual filaments 13 are suffused or bathed sufiicientIy'with-the bindingagen't to j cause the deposition thereon'of onlyla relatively rid it of large water or air pockets, its weight is 53 pounds. And finally, after drying, the

about 15 pounds-a reduction irom its original heavy, soggy mass oi 63 pounds. or over 8 0% The space formerly occupied by water-one-can I I v theiinal step." unit is isplaced in dryer 'Gand freed oi moisture. Thereafter, the 'unit may be cut to desired size and shape.

. In substantiation oi ciaims' of marked supe- Zriority' o! my invention over 85% magnesia," it is notdeemed to refer to the resultsoi sor Gordon B. Wilkes, oi Massachusetts Institute Thezmai mducti'vituflie coemcient of ther Thickness under test;2.0ii inches. Bulk density, dry, 10.5 lbs. cu. it: in

- Temp. warmer surface, Em 174 Temp. cooler suria 21 Mean temperature, F---. 3-123 Ke-Coe!. thermal coupiuctivity 0.844;

m is oxpressed in 8.1:. u.. .1m, m t, 3 o

" 'Ihese'results are in Fig.

own graphically gg t' j temperature on in h Fol-tsetse. "blocks he"? I011 3 M 85% magnesia were purchased inBQS- ton, Samples of both kinds of blocks were first -.accurate1y before and ait'er each heat; treatment.

' L For these resultsthe-ttfless in v shrinkage weresdetermined:

- ,Thebre'aking loa was determine V appreciate that it'is very considerable-becomes an exceedingly light, micro-cellular structure with a bulk density of l4 =.3 pounds per cubic.

comparative tests conducted recently by Proies'- j 01' Technology, Cambridge", Massachusetts.

" malconductivity oi the insulation constituting" the subject matter oi the present invention was determined by theguarded plate method-the samples having been dried previousto being; placed in. the tester -with-the. toll wing results" in which "x" designates the'instant inven'tion. i And ior comparison, thefapproximate range of ."x" insulation were submitted and similar blocks 5 driedand then heated iorfi hours 'at'500' E, 600;

"E. and 700, F.- ,Thr'ee-biocks of each kindwere 4 careiullyl weighed and the length -det ermin'ed is 78"pounds. Subsequent to curing, its weight weight of a single unit'is reduced to a low of U- UUWIFUOI l IVIIUI "I w v l lvlvl Ulll' PLASTIC 2,809,206 i thin coating lt-iust enough to bind the iilaing the blocks on 10 inch centers and gradually ments together and leave therebetween the applying a load in the middle until rupture occountless interstices or voids li-see Fig. 4. curred. The results. are the average of three Moreover, the initial setting of the filaments or determinations on each type of material. fibers so acquired at this point is preserved throughout the'subsequent stages of the process.

Next in order.the bar or other desirably-shaped x units, as It in Fig. 3, is transferred to a truck II or equivalent support, and then introduced Pmmfloginnisht g 'g into pressure chamber P. where it is subjected 1 to a minimum or 120-125 pounds saturated steam pressure-as opposed to dryor superheated steam, because the latter would arrest the chemigg. 3-9 cal reaction-for approximately 10 hours to nice 0144 thoroughly cure the product. During this stage otthe process, a further induration of crystallization of the binder ensues. "-F-i'f' Using approximately the proportions herein- 85%mag beforegiven, i. e., stos 80 poundsrcement Y m tit-pounds: slipaizpounds; andwaterfii galions or 625 pounds; 8 blocks or units are pro- .PM M' 46 n duced, and each unitr'n'easures a scant 86% AmF566 'L. '"IIIIIIIIIIII so 12 inches in length, 12% inches in width. and 8% f Q$$I g 2 inches in thickness. After the slurry is .s T "f I placed in the mould and lightly compressed to The above results are shown graphically m Fi .6 of the ccomp nyin drawing -"x" indi.-.

eating the instant invention.

; Another test conducted by sm'bur Foundation, .amliated with nlinois'lnstitute of Technology. proved .that my heat-insulating structure did not calcine until the temperature mm; and the "inan electric iurnac' 600' R, for magnesia.

"1- .2; The herein described process reached l86 0 F as against- ;;I t,should'be understoodthat in its broader aspects, my invention comprehends the employ-. ment not onhr oi the various means described; v but of equivalent means for accomplishing the, '1 same or approximate result. For example,'-the term fasbestos flber is employed in a generic sense. Rock wool, mineral wool, or like mineral fibers, may be used instead. Then too, the product may be used to insulate low temperatures; Or the curing may bedevised in some other man'- ner." It is desired to reserve the right to sheet such' changes, modifications or variations as may come iairlywithimthe scope of the appended The pr'ese'nt application-is a .conthijuation, in. part at my co-pending application Serial No.

.. 370,910, 'iiled December 20, l 940.. 1 i '5 f. Ii T V l. The hereinidescribed process of producing fibrous insulation, which is characterized by mix-3 x I ing'flne-mineral fibers in asuspension of water and abindereon'sisting oi'cement and silicious j material in whichonly suflicient binder is held in I j suspension, to coat thinly the fibers, depositing. 7 the resultantslurry in a mold, lightly compressing it toeliminate any unduly large entrapments ,oi--w a'ter. or air, causing thesame tovdrain; curing the mass in the presence of shriztkcaeaud fiibrous insulation, which comprises denberizing 4 asbestos .into itsapproximate ultimate filaments, I mixing with said filaments a mixture otwater and a hinder'consisting oi cement and silicious material'and 'i'n' which'mixture only suflicient binder is held. in suspension 'toco'at thinly the fliaments,- A depositing. the resultant slurry in a mold, lightly I compressing it to eliminate anyi nduly'largeentrapments 01 water orair. causing the same to] 1;-

11 .drain,.curing themass inthejipresence oisatu s pporteflc rated stea "when h Pro ct LAGIIIIIIBI' u atedstea andthen drying-the PTOdilCt- 3' -.I.' f"

of Producing '3. The herein described process of producing fibrous insulation, which comprises expanding asbestos into its approximate ultimate filaments,

mixing with said filaments a mixture of water and a binder consisting of cement and silicious material, depositing the resultant slurry in amold,

, compressing it at about 250 pounds per square inch, causing the same to drain, curing the mass Z in a chamber supplied with saturated steam, and

then drying the product.

4.,The herein described process of producing fibrous insulation, which comprises defiberizing asbestos into its approximate ultimate filaments. mixing with said filaments a mixture oi! water a and a binder consisting of cement and pulverized silicious material, depositing the resultant slurry in a mold, lightly compressing it to eliminate any mate filaments, 42 parts of cement, 12 parts of silicious material and 625 parts of water, agitating the mixture, depositing'the resultant slurry in a mold, lightly compressing it to eliminate any unduly large entrapments or water or air, causing the same to drain, curing the mass in the presence oi. saturated steam, and then drying the product.

. NATHAN E. NEWMAN.

unduly large entrapments of water or air, cans-- 

